Design Engineer Mechanical

KASTHURI SANKAR DAMODHARAN

***** *********** **, ****, ** 48377. Phone: 585-***-****. Email: ***************@*****.*** Professional Summary

Innovator with 6 US patents, multiple innovation awards, more than 12 years of experience designing electro-mechanical products with in-depth knowledge in material, mechanics, manufacturing processes, & engineering processes/tools, good customer relationships with NA OEMs, team player, mentored design engineers and managed multiple projects Area of Expertise

Researching, conceptualizing and designing electro-mechanical products for Automotive or Industrial or Medical applications

Connector design, DRBFM, DFMEA, Tolerance stack up and FEA studies

Creating detailed mechanical drawings for components and assemblies using GD&T principles (Datum selection, dimensioning and tolerance aligned with function) and BOM (Bill of Materials).

Designing injection molded parts, sheet metal, machined components and test fixtures.

Stage Gate process (Concept to Production)

In-depth knowledge in USCAR-2, 21, 25 & GMW 3191 spec Technical Skills

Creo 4.0, CATIA V5, Solidworks

Finite Element Analysis (FEA) – Creo Simulation Live, Mentat (Sumitomo), Solidworks Simulation, ANSYS, Design Discovery (TE Connectivity)

GM Teamcenter, Honda’s Drawing Support Systems (DSS)

Windchill PDMLink, PLM, CDAM & eMACS and Solidworks ePDM Certification

Certified in Six Sigma Green Belt from American Society for Quality (ASQ)

Certified on Design for 6σ Black Belt. Participated and audited on APQP and TS 16949.

Certified in Project Management from Worcester Polytechnic Institute.

Certified on VDA 6.3 (German Quality Management Center), Formel Q (VW Supplier Quality Management). Professional experience

Senior R&D/Product Development Engineer in TE Connectivity at Troy, MI, US

(June 2018 – June 2020)

o Developed documentation of the project scope, requirements, feasibility, & engineering work plan. Worked directly with product management & the customer to capture needs and translates into an executable project

o Experienced in designing general or customized new and sustaining (low voltage and high voltage) electromechanical product for NA OEMs

o Provided technical support for investigating customer complaints pertaining to electromechanical failure during mule or production builds, Lead root cause analysis utilizing structured problem solving methods

(8D, 5 Why, Fishbone)

o Conducted gap analysis between the North American specs (USCAR/GMW) vs. European spec (LV214) o Presented differences on previous versions in GMW 3191 & USCAR specs to cross functional teams o Acted as the voice of engineering to cross functional team members and customers to ensure design objectives are met.

o Conducted and lead internal DRBFM, DFMEA, reviews with internal and external customers using effective verbal and written communication skills

o Communicated and written instructions to the test lab technicians on the test setup and procedure for the DV & PV level of testing

o Worked with global manufacturing resources, procurement, and outside suppliers to meet all TE technical, quality, and cost objectives

Lead Design Engineer in Sumitomo Electric Wiring Systems at Farmington Hills, MI, USA

(May 2016 – May 2018)

o Responsible for conceptualizing, designing new and sustaining electromechanical products for North American Auto Manufacturers

o Lead the team during new product development, product design, documentation, prototype & production validation, procurement of crimped leads/terminals etc. o Conducted technical design reviews and manage multiple projects to meet customer and internal deadlines

o Responsible for the compliance with design standards and regulatory requirements o Developed test plans (DVP&Rs) to validate product performance and analyze test results using statistical methods DOEs, Hypothesis Testing, Capability Studies o Created a Test plan as per customer requirement, investigate the root cause for product failures and implement design change

o Prepared instruction manuals for wire harness suppliers & external customers

Senior Design Engineer in JAE Oregon at Tualatin, OR, USA

(July 2013 – April 2016)

o Responsible for designing and developing a general release airbag connector (AK2 and AK3) for European and American auto manufacturers

o Conduct and lead DFMEA, Tolerance and FEA studies for new and customized products o Lead and initiated on R&D activities between the suppliers and cross-functional teams in JAE o Support new product development activities (for Ford, BOSCH, TRW or Daimler) during initial RFQ phase

o Responsible for drafting Electrical Harnesses for Honda using DSS tool in CATIA o Audit supplier sites with regards to VDA 6.3 compliance

Product Development Engineer in TE Connectivity at Harrisburg, PA, USA

(Feb 2008 – Jan 2013)

o Managed all phases of the design process for a multitude of products, including drafting, dimensioning and tolerance studies, proto-typing and documenting results o Designed multiple custom connectors for Gyrus ACMI Receptacle Connector, Richard Wolf (RW) Adapter and Receptacle connectors considering all the customer requirements o Conceptualized and designed low cost, general release & single use version of Medical Circular Plastic Connector (MCPC) that can be manufactured in any capacity o Conducted Voice of the customer, designed and developed M12 product lines with IEC 61076-2-101 standards. Coordinated with UL standards committee for product compliance o Collaborated with IEC Committee to standardized H-Code (TE proposed) as a new industrial high speed M12 code for M12 10G product line

Patents

K. Damodharan “Connector housing assembly having an anti-rotational locking structure” (US Patent No. 10630016), April 2020

K. Damodharan, A. Kennedy, G. Letourneau, K. Okuda “Self-rejecting automotive harness connector” (US Patent No. US8968021B1), March 2015

K. Damodharan, M. Wilbourn “Contact assembly for electrical connector” (US Patent No. 8460024), June 2013

K. Damodharan, S. Millard, M. Shanbhag, B. Williams “Pluggable connector with differential pairs having an air core” (US Patent No. US8241068B2), March 2012

K. Damodharan, R. Walker “Low profile contact” (US Patent No. US7934961B2), May 2011

K. Damodharan, W. Lenker, B. Williams “Push-pull connector” (US Patent No. 7806714), October 2010 Education

Master of Science in Manufacturing & Mechanical Systems Integration Rochester Institute of Technology (RIT), Rochester, NY, USA Dec 2007 o Graduate scholarship, 2005 - 2007

Bachelor of Engineering in Mechanical Engineering Anna University, India Jun 2003

Contact this candidate